There are described a semiconductor inspection system for inspecting recessed defects formed in a semiconductor wafer and a semiconductor device manufacturing method including an inspection step of inspecting recessed defects formed in a semiconductor wafer. The semiconductor inspection system and the semiconductor device manufacturing method enable the following operations: an operation of radiating a laser beam onto a semiconductor wafer; an operation of detecting light scattered from foreign particles, as a result of a laser beam being radiated onto the semiconductor wafer; an operation of converting the detected scattered light into an electric signal; and an operation of outputting information about the recessed defects formed in the semiconductor wafer by means of subtracting the data pertaining to only the foreign particles located on the semiconductor wafer from the data pertaining to both the foreign particles and recessed defects formed in the semiconductor wafer.
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6. A method of manufacturing a semiconductor device comprising the steps of:
radiating a laser beam onto a semiconductor wafer to be measured; detecting light scattered from foreign particles or recessed defects formed in the semiconductor wafer, as a result of a laser beam being radiated onto the semiconductor wafer and converting the detected scattered light into an electric signal; processing the electric signal in the form of data; and outputting information about the recessed defects formed in the semiconductor wafer by means of subtracting the data pertaining to only the foreign particles located on the semiconductor wafer from the data pertaining to both the foreign particles and recessed defects formed in the semiconductor wafer.
1. A semiconductor device inspection system comprising:
a laser beam radiation section for radiating a laser beam onto a semiconductor wafer to be measured; a detection section which detects light scattered from foreign particles or recessed defects formed in the semiconductor wafer, as a result of a laser beam being radiated onto the semiconductor wafer, and converts the detected scattered light into an electric signal; and a control section for processing the electric signal in the form of data, said control section outputting information about the recessed defects formed in the semiconductor wafer, by means of subtracting the data pertaining to only the foreign particles located on the semiconductor wafer from the data pertaining to both the foreign particles and recessed defects formed in the semiconductor wafer.
4. A semiconductor device inspection system comprising:
a laser beam radiation section for radiating a laser beam onto a semiconductor wafer to be measured; a detection section which detects light scattered from foreign particles or recessed defects formed in the semiconductor wafer as a result of a laser beam being radiated onto the semiconductor wafer and converts the detected scattered light into an electric signal; and a control section for processing the electric signal in the form of data, wherein the laser beam radiation section can radiate a laser beam onto the primary surface of the semiconductor wafer by selection of either a normal direction or an oblique direction, and the control section can output information about the recessed defects formed in the semiconductor wafer, by means of subtracting the data pertaining to only the foreign particles located on the semiconductor wafer from the data pertaining to both the foreign particles and recessed defects formed in the semiconductor wafer.
9. A method of manufacturing a semiconductor device comprising the steps of:
radiating a laser beam onto a semiconductor wafer to be measured in a normal direction, detecting light scattered from foreign particles or recessed defects formed in the semiconductor wafer, as a result of a laser beam being radiated onto the semiconductor wafer, and converting the detected scattered light into an electric signal, to thereby prepare data pertaining to both foreign particles and recessed defects formed in the semiconductor wafer; radiating a laser beam onto the primary surface of the semiconductor wafer in an oblique direction, detecting the light scattered from foreign particles located on the semiconductor wafer when the laser beam is radiated onto the foreign particles, and converting the detected scattered light into an electric signal, to thereby prepare data pertaining to solely foreign particles located on the semiconductor wafer; and outputting information about the recessed defects formed in the semiconductor wafer by means of subtracting the data pertaining to only the foreign particles located on the semiconductor wafer from the data pertaining to both the foreign particles and recessed defects formed in the semiconductor wafer.
2. The semiconductor inspection system according to
the data pertaining to both the foreign particles and recessed defects formed in the semiconductor wafer are prepared by means of referring to a sensitivity calibration curve representing a relationship between recessed defects and intensity of light scattered from the recessed defects.
3. The semiconductor inspection system according to
the sensitivity calibration curve representing a relationship between recessed defects and intensity of light scattered from the recessed defects is prepared through use of a reference wafer in which recessed defects are artificially formed.
5. The semiconductor device inspection system according to
the data pertaining to both foreign particles and recessed defects formed in the semiconductor wafer are prepared by means of a laser beam being radiated onto the primary surface of the semiconductor wafer in a normal direction relative to the primary surface.
7. The method of manufacturing a semiconductor device according to
the data pertaining to both the foreign particles and recessed defects formed in the semiconductor wafer are prepared by means of referring to a sensitivity calibration curve representing a relationship between recessed defects and the intensity of light scattered from the recessed defects.
8. The method of manufacturing a semiconductor device according to
the sensitivity calibration curve representing a relationship between recessed defects and intensity of light scattered from the recessed defects is prepared through use of a reference wafer in which recessed defects are artificially formed.
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1. Field of the Invention
The present invention relates to a semiconductor inspection system for inspecting defects, such as recesses in a semiconductor wafer, as well as to a method of manufacturing a semiconductor device including a step of inspecting recesses in a semiconductor wafer.
2. Background Art
If foreign particles or defects arise in a semiconductor wafer, the foreign particles or defects causes an impediment in a process of manufacturing a semiconductor device from a semiconductor wafer. Further, such foreign particles or defects exert significant influence on the characteristic of the semiconductor device manufactured from the semiconductor wafer. An inspection step of measuring the size and density of foreign particles present on a semiconductor wafer is indispensable for the process of manufacturing a semiconductor device.
The conventional semiconductor inspection system shown in
On the basis of a flowchart shown in
First, a reference wafer to be used for inspecting an foreign particle as shown in
The sizes of different foreign particles provided on the reference wafers are measured, through use of the semiconductor inspection system shown in FIG. 10. The reference wafer is inspected by means of a laser beam being radiated, in a scanning manner, on the semiconductor wafer 1 from the laser beam radiation section 2. The detection (PTM) section 5 detects the intensity of the light scattered from the semiconductor wafer 1. At this time, the relationship between intensity of scattered light and the resultant count value is plotted for each reference wafer, as shown in FIG. 11B.
On the basis of the graph relating to the relationship between intensity of scattered light and the resultant count value, the graph being defined for each of the reference wafers coated with a foreign particle of a different size, the intensity of scattered light corresponding to the maximum count value is defined as the intensity of scattered light for a foreign particle of each size.
Next, a sensitivity calibration curve is prepared. As shown in
A real wafer which is to be actually subjected to foreign particle inspection is measured, whereby the relationship between the intensity of scattered light and the resultant count value is examined. By reference to the sensitivity calibration curve, there is performed computation of foreign particle data; that is, estimation of distribution (i.e., the sizes and locations) of foreign particles on the real wafer.
The conventional semiconductor inspection system and the conventional foreign particle inspection method have been embodied as mentioned previously.
The conventional system and method enable measurement of foreign particles which are present on a wafer surface in the form of projections. In a case where crystal-originated particles (COPs), which are crystal imperfections of a wafer, or recesses, such as micro-scratches formed during a chemical-mechanical polishing step during wafer processing, are present on a wafer, the conventional system and method encounter the following problems.
The light scattered from recessed defects or damage of a wafer is weaker than the light scattered from projecting foreign particles which are present on a wafer surface. In a case where foreign particles and recessed defects are mixedly present on a wafer, even when an attempt is made to measure only recessed defects, both foreign particles and recessed defects are measured. Thus, sharp, distinctive indication of only recessed defects is infeasible.
The present invention has been conceived to solve the drawback of the background art as described above and is aimed at providing a semiconductor inspection system which can sharply distinguish recesses from foreign particles on a wafer and measure the distribution of recessed defects, such as crystal imperfections or damages, over a wafer while the size and position of desired defects are specified. Further, the present invention is aimed at providing a semiconductor device manufacturing method including an inspection step of inspecting defects of a semiconductor wafer through use of the foregoing semiconductor inspection system.
According to one aspect of the present invention, a semiconductor device inspection system comprises a laser beam radiation section, a detection section and a control section. The laser beam radiation section radiates a laser beam onto a semiconductor wafer to be measured. The detection section detects light scattered from foreign particles or recessed defects formed in the semiconductor wafer, as a result of a laser beam being radiated onto the semiconductor wafer, and converts the detected scattered light into an electric signal. Further, the control section processes the electric signal in the form of data, and outputs information about the recessed defects formed in the semiconductor wafer, by means of subtracting the data pertaining to only the foreign particles located on the semiconductor wafer from the data pertaining to both the foreign particles and recessed defects formed in the semiconductor wafer.
According to another aspect of the present invention, a semiconductor device inspection system comprises a laser beam radiation section, a detection section and a control section. The laser beam radiation section radiates a laser beam onto a semiconductor wafer to be measured. The laser beam radiation section can radiate a laser beam onto the primary surface of the semiconductor wafer by selection of either a normal direction or an oblique direction. The detection section detects light scattered from foreign particles or recessed defects formed in the semiconductor wafer as a result of a laser beam being radiated onto the semiconductor wafer and converts the detected scattered light into an electric signal. The control section processes the electric signal in the form of data, and outputs information about the recessed defects formed in the semiconductor wafer, by means of subtracting the data pertaining to only the foreign particles located on the semiconductor wafer from the data pertaining to both the foreign particles and recessed defects formed in the semiconductor wafer.
According to still another aspect of the present invention, in a method of manufacturing a semiconductor device, a laser beam is radiated onto a semiconductor wafer to be measured. Light scattered from foreign particles or recessed defects formed in the semiconductor wafer is detected, and the detected scattered light is converted into an electric signal. The electric signal is processed in the form of data, and outputted is information about the recessed defects formed in the semiconductor wafer by means of subtracting the data pertaining to only the foreign particles located on the semiconductor wafer from the data pertaining to both the foreign particles and recessed defects formed in the semiconductor wafer.
According to further aspect of the present invention, in a method of manufacturing a semiconductor device, a laser beam is radiated onto a semiconductor wafer to be measured in a normal direction, and light scattered from foreign particles or recessed defects formed in the semiconductor wafer is detected. The detected scattered light is converted into an electric signal, to thereby prepare data pertaining to both foreign particles and recessed defects formed in the semiconductor wafer. Further, a laser beam is radiated onto the primary surface of the semiconductor wafer in an oblique direction, and the light scattered from foreign particles located on the semiconductor wafer is detected. The detected scattered light is converted into an electric signal, to thereby prepare data pertaining to solely foreign particles located on the semiconductor wafer. Then, outputted is information about the recessed defects formed in the semiconductor wafer by means of subtracting the data pertaining to only the foreign particles located on the semiconductor wafer from the data pertaining to both the foreign particles and recessed defects formed in the semiconductor wafer.
Other and further objects, features and advantages of the invention will appear more fully from the following description.
FIG. 1A and
FIG. 2 and FIG. 2A through
FIG. 3A through
FIG. 7A and
FIG. 8A and
FIG. 9A through
FIG. 10A and
Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings. In the drawings, the same or corresponding portion are designated by same reference numerals, and detailed explanation may be omitted or simplified.
First Embodiment
The semiconductor inspection system shown in
The console section 11 performs mechanical actuation of a device, such as transportation of a semiconductor wafer. The inspection section 12 has a function of inspecting recessed defects in a semiconductor wafer.
Reference numeral 2 designates a laser radiation section for radiating a laser beam onto the semiconductor wafer 1. The laser radiation section 2 can radiate a laser beam onto the semiconductor wafer 1 while scanning the same. Reference numeral 3 designates a reflection section for reflecting the light scattered from foreign particles on or recesses in the semiconductor wafer 1; and 4 designates a light converging section for converging the light reflected from the reflection section 3. An optical lens is used for the light converging section 4. Reference numeral 5 designates a detection section for converting the thus-converged light into an electric signal. A photo-multiplier (PTM) is used for the detection section 5.
Explanation will now be given of a step S1 of preparing a reference wafer, by reference to the flowchart showing recessed defect inspection procedures shown in
The reference wafer (
Similarly, the reference wafer (
Turning again to
The method of preparing data pertaining to reference wafers to be used for measuring foreign particles is the same as that described in connection with the background art. For each of PSL particle sizes, the relationship between intensity of scattered light and the resultant count value is plotted.
A method of measuring reference wafer to be used for measuring reference wafers to be used for measuring recessed defects is in principle the same as that used for measuring reference wafers to be used for measuring foreign particles. For any of the types of reference wafers to be used for measuring recesses described previously, a plurality of reference wafers are prepared, each wafer having recesses of a different size formed therein. The laser beam radiation section 2 radiates a laser beam on each of the reference wafers while scanning the same, through use of the semiconductor inspection system. The intensity of the light scattered from the wafer is detected by the detection section 5. At that time, the relationship between intensity of scattered light and the resultant count value is plotted for each of the reference wafers. Subsequently, on the basis of the relationship between intensity of scattered light and the resultant count value, the relationship being plotted for each of the plurality of reference wafers having recesses of difference sizes (i.e., difference diameters), the intensity of scattered light corresponding to the maximum count value is defined as the intensity of scattered light for a recess of the corresponding size.
Subsequently, in the step S3 of preparing a sensitivity calibration curve as shown in
In the step S4 of measuring a real wafer shown in
In the step S5 of calculating defects shown in
The technique of computing the distribution of defects over the real wafer will be described in detail by reference to
As shown in
As shown in
In this way, the distribution of recessed defects which are present in a wafer surface can be measured in the first embodiment. The computing operation, storage of computation results, and output of the same are controlled by the control section 10 of the semiconductor inspection system.
Second Embodiment
In the first embodiment, there is employed the technique of preparing data pertaining to solely recessed defects, by means of subtracting the data pertaining to only foreign particles, as measured through use of the foreign particle sensitivity calibration curve, from the data pertaining to foreign particles and recessed defects, as measured through use of recessed defect sensitivity calibration curve.
The present embodiment describes another method of sharply distinguishing foreign particles from recessed defects.
In the second embodiment, in a step S3 corresponding to the real wafer measurement step employed in the first embodiment (FIG. 2), a laser beam is radiated onto the primary surface of a semiconductor wafer to be measured, from a normal direction and in a scanning manner, to thereby acquire data pertaining to foreign particles and recessed defects which are present on the wafer. Similarly, there are obtained data pertaining to foreign particles located on the wafer. As shown in
As shown in
Third Embodiment
In a process of manufacturing a semiconductor device, recessed defects formed in a semiconductor wafer are usually inspected, and selected wafers are loaded into processing steps. The step of measuring the distribution of recessed defects formed in a semiconductor wafer, which has been described in connection with the first and second embodiments, is used in an inspection step to be performed before a semiconductor wafer is loaded into processing steps. A predetermined wafer processing step and an assembly step are performed after such an inspection step. According to such a method of manufacturing a semiconductor device, a semiconductor wafer--in which inappropriate recessed defects have arisen during the course of fabrication of a semiconductor device--can be removed before it is loaded into processing steps. Thus, factors which would otherwise induce failures can be removed in advance, thereby improving the manufacturing yield of a semiconductor device. Further, a semiconductor device manufactured through such manufacturing processes is characterized by stable characteristics and high reliability.
The step of measuring recessed defects formed in a semiconductor wafer can be performed not only in the inspection step to be performed before a wafer is loaded into a semiconductor wafer processing step, but also at any position in the course of semiconductor wafer processing step. For example, after deposition of a dielectric film, such as a silicon oxide film, on a semiconductor wafer, the distribution of recessed defects formed in the dielectric film can be examined. Further, the step can be employed in a step of inspecting a resist film which has been applied over a semiconductor wafer, in a photolithography process. As mentioned above, so long as the step of measuring recessed defects is performed in the course of the wafer processing step, the distribution of recessed defects which have arisen in the course of the wafer processing step can be grasped. As a result, semiconductor wafers in which defects have arisen can be removed in advance, thereby improving the manufacturing yield of a semiconductor device. Further, a semiconductor device manufactured through such manufacturing processes is characterized by stable characteristics and high reliability.
The inspection step of inspecting recessed defects according to the present invention can be used not only in a process of manufacturing a semiconductor device, but also in a process of manufacturing another device, such as a liquid-crystal panel.
As has been described, the semiconductor inspection system according to the present invention yields an advantage of ability to sharply distinguish foreign particles located on a substrate to be measured from recessed defects formed in the same, thereby readily providing data pertaining to the distribution of recessed defects located in the substrate.
In the method of manufacturing a semiconductor device according to the present invention, recessed defects formed in a semiconductor wafer are inspected during a process for fabricating a semiconductor device, through use of the semiconductor inspection system, thereby improving the manufacturing yield of a semiconductor device and the reliability of the same.
Obviously many modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may by practiced otherwise than as specifically described.
The entire disclosure of a Japanese Patent Application No. 2000-090920, filed on Mar. 29, 2000 including specification, claims, drawings and summary, on which the Convention priority of the present application is based, are incorporated herein by reference in its entirety.
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